JP2010538964A - Synthesis of highly active ZSM-48 - Google Patents

Abstract

A method for producing ZSM-48, comprising: at least one silica source, at least one alumina source, at least one hydroxyl ion source, the formula (CH ₃ ) ₃ N ⁺ (CH ₂ ) ₅ N ⁺ ( Crystallizing an aqueous reaction mixture comprising at least one ion source of diquaternary alkylammonium (R ²⁺ ) ions represented by CH ₃ ) ₃ and an optional ZSM-48 seed crystal, said reaction mixture ^Has a composition comprising the following molar ratios: R ²⁺ : SiO ₂ less than 0.1 and SiO ₂ : Al ₂ O ₃ less than 100.
[Selection] Fig. 5-A Fig. 5-B

Description

  The present invention relates to the synthesis of high activity ZSM-48 and its use as a catalyst, especially in the dewaxing of hydrocarbon feedstock.

  ZSM-48 is a zeolite with orthorhombic or pseudoorthogonal symmetry and has a 10-ring discontinuous linear passage whose ideal dimension is 5.5 × 5.6 mm. ZSM-48 exhibits attractive properties as a catalyst for dewaxing hydrocarbon feedstock. For example, see Patent Document 1, Patent Document 2, and Patent Document 3. As a result, there is considerable interest in finding new methods for synthesizing ZSM-48, and ZSM-48, which has particularly high acid activity (ie, low silica / alumina molar ratio).

ZSM-48 is first by Rollmann et al, was synthesized using the _C 4 _{-C 12} organic diamine as structure directing agent. See Patent Document 4. When synthesized by Rollman et al., The zeolite contained little or no aluminum and therefore had little acid activity.

Also the ZSM-48 having a molar ratio of higher silica / _alumina, it can be synthesized in the presence of a mixture of C 2 _{-C 12} alkylamines and _C 3 -C ₅ tetramethylammonium compounds are described in Patent Document 5, Synthesis in the presence of a bis (N-methylpyridyl) ethylinium cation is described in US Pat.

  Patent document 7 discloses synthesizing ZSM-48 in the presence of ethylenediamine as a structure directing agent. However, the broad definition of the reaction mixture requires a silica / alumina molar ratio of at least 100, and the only example where the composition of the ZSM-48 product is cited (Example 2) is that the silica / alumina molar ratio is Report 170.

Patent Document 8 describes ZSM-48 as a general formula:
[(R ′) ₃ N ⁺ (Z) _m [(R ′) ₃ N ⁺ ] (X ⁻ ) ₂
Wherein each R ′ is an alkyl or heteroalkyl group having 1 to 20 carbon atoms, a cycloalkyl or cycloheteroalkyl group having 3 to 6 carbon atoms, or an aryl or heteroaryl group; , An alkylene or heteroalkylene group having 1 to 20 carbon atoms, an alkenylene or heteroalkenylene group having 2 to 20 carbon atoms, or an arylene or heteroarylene group; m is 5, 6, 8, 9, or And X ⁻ is an anion.
Is disclosed in the presence of certain linear diquaternary compounds having: U.S. Patent No. 6,057,059 reports that the silica / alumina molar ratio of the reaction mixture must be at least 100 because lower values produce different silicate frameworks.

Patent Document 9 _discloses a pure phase ZSM-48 crystals with XO _{2 /} Y _{2 O 3} ratio of less than about 150/1. In the formula, X is at least one of Si or Ge (preferably Si), and Y is at least one of Al, Ga, B, Fe, Ti, V, and Zr (preferably Al). It is free of ZSM-50 and Kenyaite impurities having a diameter of less than about 1 micron and is substantially free of fibrous tissue. The material is at least one organic template material selected from organic linear diquaternary alkylammonium compounds and linear diaminoalkanes, and ZSM-5, ZSM-11, ZSM-12, colloidal BEA, beta, X, and Produced by crystallizing a reaction mixture containing a heterostructure zeolite seed selected from Y zeolite. Examples are the hexamethonium chloride used as a linear diquaternary alkyl ammonium compound, to produce a ZSM-48 crystals with a molar ratio of lower _SiO 2 / _Al 2 _{O 3} of about 67.7.

  U.S. Patent No. 6,057,031 discloses the synthesis of a composition having a ZSM-48 crystal having a silica: alumina molar ratio of 110 or less, no non-ZSM-48 crystals and no ZSM-50. This is by crystallizing a reaction mixture comprising an aqueous mixture of silica or silicate, alumina or aluminate, hexamethonium salt, and alkali base. The reaction mixture then has the following molar ratio: That is, the molar ratio of silica: alumina is 70-110, the molar ratio of base: silica is 0.1-0.3, and the molar ratio of hexamethonium salt: silica is 0.01-0.05. The production of ZSM-48 crystals having a silica: alumina molar ratio as low as 80 is illustrated.

Non-Patent Document 1 describes the effect of a synthesis variable. In particular, the type and concentration of alkali ions for the phase selectivity of zeolite crystallization in the presence of Me ₆ -diquaternary-n ions (where n varies from 3 to 10). In particular, Non-Patent Document 1 uses a synthetic mixture that contains Me ₆ -diquaternary-5 and has a silica / alumina molar ratio of 60 and a diquaternary / silica molar ratio of 0.1 in Table 2. Thus, crystallization produces ZSM-48 when the mixture has an OH ⁻ / SiO ₂ molar ratio of 0.33 or less, but at an OH ⁻ / SiO ₂ molar ratio of 0.47, ZSM-12 , And OH ⁻ / SiO ₂ molar ratios of 0.6 and 0.73 have been reported to produce MCM-22. At even higher OH ⁻ / SiO ₂ molar ratios, the product is mordenite and / or borofluorite.

In accordance with the present invention, where in the synthesis of highly active ZSM-48 using Me ₆ -diquaternary-5 as structural propellant, the diquaternary / silica molar ratio affects the phase selectivity of the product. It has been found to be a critical variable to give. Furthermore, Me 6 _- diquaternary -5 and Me 6 _- by using a combination of diquaternary -6 as structure directing agents, it is possible to control the structure of the resulting ZSM-48 crystals Heading Has been.

US Pat. No. 5,075,269 US Pat. No. 6,884,339 International Publication No. 01/64339 Pamphlet US Pat. No. 4,423,021 US Pat. No. 4,397,827 US Pat. No. 4,585,747 US Pat. No. 5,961,951 European Patent Application No. 142317A US Pat. No. 6,923,949 International Publication No. 2007/070521 Pamphlet

Song-Ho Lee et al., “Reinvestigation into the synthesis of ze ol s er er m er er m er er er m er er er m er er m er er m er er m er n er er er er er m er er m 97-104, 2004)

In one aspect, the invention belongs to a method for producing ZSM-48, which method comprises:
(A) at least one silica source, at least one alumina source, at least one hydroxyl ion source,
(CH ₃ ) ₃ N ⁺ (CH ₂ ) ₅ N ⁺ (CH ₃ ) ₃
An aqueous reaction mixture comprising at least one ion source of ^diquaternary alkylammonium (R ²⁺ ) ions represented by and an optional seed crystal, wherein the reaction mixture has the following molar ratio:
R ^2+: _SiO 2 0.1 than SiO _{2: Al} 2 _O 3 less than 100 OH ^-: step has a composition comprising less than _SiO 2 0.2, and (b) the reaction mixture, to produce the ZSM-48 And crystallizing under effective conditions.

Conveniently, the reaction mixture has the following molar ratio:
R ²⁺ : SiO ₂ about 0.01 to about 0.05
SiO ₂ : Al ₂ O ₃ less than about 50 to 100 OH ⁻ : SiO ₂ about 0.1 to about 0.2
It has the composition containing.

Conveniently, the reaction mixture has a H ₂ O: SiO ₂ molar ratio of less than 30 and in one embodiment also comprises a sodium cation source, typically the mixture of Na ⁺ : SiO ₂ Having a molar ratio of less than 0.2.

Conveniently, the reaction mixture also has the following formula: (CH ₃ ) ₃ N ⁺ (CH ₂ ) _n N ⁺ (CH ₃ ) ₃ , wherein n is 3, 4, 6, 7, 8, 9 Or an ion source of diquaternary alkylammonium ions represented by:

In a further aspect, the present invention belongs to a method for producing ZSM-48, the method comprising at least one silica source, at least one alumina alumina source, at least one hydroxyl ion source,
(CH ₃ ) ₃ N ⁺ (CH ₂ ) ₅ N ⁺ (CH ₃ ) ₃
At least one ion source of a first diquaternary alkylammonium ion represented by the formula:
(CH ₃ ) ₃ N ⁺ (CH ₂ ) _n N ⁺ (CH ₃ ) ₃
[Wherein n is 3, 4, 6, 7, 8, 9, or 10, especially 6]
Crystallizing an aqueous reaction mixture comprising a second diquaternary alkylammonium ion having at least one ion source and any seed crystals.

Conveniently, the reaction mixture has a SiO ₂ : Al ₂ O ₃ molar ratio of less than 100.

Conveniently, the molar ratio of (total diquaternary alkylammonium ions: SiO ₂ ) in the reaction mixture is less than 0.1.

  In all of the above embodiments, the reaction mixture preferably comprises a seed crystal, more preferably a ZSM-48 seed crystal. Conveniently, the ZSM-48 seed is present in an amount from about 50 wppm to about 50,000 wppm of the reaction mixture.

  Conveniently, the crystallization conditions comprise a temperature of about 120 ° C. to about 200 ° C. for about 12 to about 200 hours.

  In yet another aspect, the present invention belongs to a method for dewaxing a hydrocarbon feedstock, wherein the method comprises converting a hydrocarbon feedstock to a ZSM-48 prepared by the method described herein. And contacting under dewaxing conditions.

FIG. 2 is an X-ray diffraction pattern for the as-synthesized product of Example 1. FIG. 2 is a scanning electron micrograph (SEM) of the as-synthesized product of Example 1. FIG. 5 is an X-ray diffraction pattern for the as-synthesized product of Example 2 (Comparative Example). Figure 2 is a scanning electron micrograph (SEM) of the as-synthesized product of Example 2 (Comparative Example). FIG. 5 is an X-ray diffraction pattern for the as-synthesized product of Example 4. FIG. FIG. 2 is a scanning electron micrograph (SEM) of the as-synthesized product of Example 4. FIG. FIG. 5 is an X-ray diffraction pattern for the as-synthesized product of Example 5. FIG. FIG. 2 is a scanning electron micrograph (SEM) of the as-synthesized product of Example 5. FIG. FIG. 5 is an X-ray diffraction pattern for the as-synthesized product of Example 6. FIG. FIG. 6 is a scanning electron micrograph (SEM) of the as-synthesized product of Example 6. FIG. In the n-decane isomerization process of Example 8, it is a graph of n-decane conversion with respect to temperature. 6 is a graph of iso-decane yield versus n-decane conversion in the n-decane isomerization process of Example 8.

  The present invention relates to a process for producing ZSM-48, particularly high activity ZSM-48 having a silica / alumina molar ratio of less than 100, and the resulting ZSM-48 as a catalyst in the dewaxing of hydrocarbon feedstock. About the use of.

In the present method, ZSM-48 comprises at least one silica source, at least one alumina source, at least one hydroxyl ion source, Me ₆ -diquaternary-5 ion (also referred to herein as penta Called methonium ion, the following formula:
(CH ₃ ) ₃ N ⁺ (CH ₂ ) ₅ N ⁺ (CH ₃ ) ₃
Of an aqueous reaction mixture containing a directing agent containing at least one ion source and any seed crystals. The aqueous reaction mixture then has the following molar ratio:
R ²⁺ : Less than SiO ₂ 0.1 (about 0.01 to about 0.05 etc.)
SiO _{2: Al} 2 _O 3 less than 100 (such as less than about 50 to 100)
OH ⁻ : Less than SiO ₂ 0.2 (about 0.1 to about 0.2, etc.)
It has the composition containing.

Generally, the reaction mixture also has an H ₂ O: SiO ₂ molar ratio of less than 30, or even less than 20. This can lead to higher yields for the desired ZSM-48 product. In one embodiment, the reaction mixture also includes a source of sodium cation, typically the reaction mixture has a Na ⁺ : SiO ₂ molar ratio of less than 0.2. A suitable sodium ion source is sodium hydroxide. This of course also provides a suitable hydroxyl ion source.

  The reaction mixture preferably contains seed crystals. Typically, it is a zeolite seed of a framework type that is different from or the same as ZSM-48. A more preferred seed crystal is a ZSM-48 seed crystal. When used, the ZSM-48 seed is generally added to the aqueous reaction mixture so as to be present in an amount of about 50 wppm to about 50,000 wppm. Generally, at least 100 wppm of the seed crystal is used. Preferably, it is 100 wppm to 5000 wppm of the reaction mixture, and more preferably 500 wppm to 3000 wppm. In one embodiment, ZSM-48 selected for use as a seed crystal has a silica / alumina molar ratio of less than 100.

  Any reactive silica can be used as the silica source in the reaction mixture, and suitable commercially available materials are fumed silica, precipitated silica, silica gel, silicic acid, tetraalkylorthosilicate. Or an aqueous colloidal suspension of silica. In general, fumed silica appears to help produce ZSM-48 having a low silica / alumina molar ratio and high purity.

  Similarly, although a water-soluble alumina source such as aluminate or an aluminum salt is generally preferred (such as aluminum nitrate), any reactive form of alumina can be used as the alumina source. Other suitable alumina sources include hydrated alumina. Such as gamma-alumina, pseudoboehmite, and colloidal alumina.

The ion source of Me ₆ -diquaternary-5 ions in the reaction mixture is dihalide (especially dichloride or dibromide) or any readily available pentamethonium salt such as pentamethonium dihydroxide. Can be.

Although this synthesis method can be used with Me ₆ -diquaternary-5 ions as the only structure directing agent, in some embodiments, at least one of the Me ₆ -diquaternary-5 ions and It may be desirable to use a mixture of different quaternary ammonium compounds as structure directing agents. In this case, the different diquaternary ammonium compounds have the following formula:
(CH ₃ ) ₃ N ⁺ (CH ₂ ) _n N ⁺ (CH ₃ ) ₃
[Wherein n is 3, 4, 6, 7, 8, 9, or 10, especially 6]
Have The Me ₆ -diquaternary-6 cation is also referred to herein as the hexamethonium cation. Thus, by using these mixtures of diquaternary ammonium compounds, and in particular mixtures of Me ₆ -diquaternary-5 ions and Me ₆ -diquaternary-6 ions, a lower silica / alumina molar ratio, and / or Or it is found that it may be possible to produce ZSM-48 with different tissues, which can be obtained using either diquaternary single. For example, Me ₆ -diquaternary-5 alone may be advantageous for the formation of ZSM-48 with needle-like or fibrous texture, but Me ₆ -diquaternary-5 ion and Me ₆ -diquaternary- A mixture of 6 ions appears to be advantageous for crystals having a lower length / diameter ratio.

When a mixture of Me ₆ -diquaternary-5 ions and at least one different diquaternary ammonium compound is used as the structure directing agent, Me ₆ -diquaternary-5 ions / the at least one different diacid. The molar ratio of the quaternary ammonium compound is generally such that Me ₆ -diquaternary-5 ions represent 10% to 90% of all diquaternary alkylammonium ions. Furthermore, the total amount of Me ₆ -diquaternary-5 ions and the at least one different diquaternary ammonium compound present during the reaction generally has a molar ratio of total diquaternary alkylammonium ions / SiO ₂ of 0. It is determined to be less than 1.

  The crystallization conditions used in this method are not strictly controlled. However, this generally includes temperatures of about 120 ° C. to about 200 ° C. (such as about 140 ° C. to about 180 ° C.), and about 12 to about 200 hours (such as about 20 to about 120 hours). Crystallization should be performed either in a static reactor or (preferably) stirring conditions in a suitable reactor vessel (eg, polypropylene jar or Teflon ™ lined or stainless steel autoclave). Can do. When crystallization is complete, the ZSM-48 product is separated from the mother liquor and recovered, typically by filtration or centrifugation.

ZSM-48 produced by this method is generally in its as-synthesized anhydride form and has the following molar composition:
_{^{(0.01~ <0.1) R 2+:}} (0.1~ <0.2) M 2 / n: xAl 2 O 3: SiO 2
[Wherein R ²⁺ is one or more diquaternary ammonium compounds (including Me ₆ -diquaternary-5), and M is an n-valent at least one alkali or alkali metal cation (particularly sodium). And x is greater than 0.01, typically greater than 0.0125 (such as about 0.013 to about 0.02)]
Have

  In its as-synthesized anhydride form, ZSM-48 produced by the present method has an X-ray diffraction pattern comprising the rows set forth in Table 1 below.

  These values were determined by standard techniques. The radiation was a copper K-alpha doublet and a diffractometer equipped with a scintillation counter with strip chart pen records was used. Peak height, intensity (I), and position were read from the spectrometer chart as a function of 2θ (θ is the Bragg angle). From these, the relative intensity, 100 I / Io (Io is the intensity of the strongest line or peak), and d (observed value), the lattice spacing (Å) (corresponding to the recorded line) were calculated. . In Table 1, the relative intensities are indicated by the “weak” symbol W, the “very strong” VS, and the “weak to strong” WS (depending on the cation type). Ion exchange of sodium ions by cations shows substantially the same pattern, but with some slight shift in lattice spacing and relative intensity variation. Other slight variations can occur depending on the silicon / aluminum ratio of a particular sample as well as when it has been subjected to heat treatment.

  The ZSM-48 product of the process generally contains water from the reaction mixture. To that end, it typically requires at least some dehydration, for example, before being used as a catalyst. Dehydration is generally accomplished by heating the as-synthesized product in the atmosphere (air, nitrogen, etc.) and at atmospheric pressure to a temperature of about 100 ° C. to about 600 ° C. for about 1 to about 48 hours. . Dehydration can also be performed at room temperature by simply placing ZSM-48 under reduced pressure, but a longer time is required to obtain a sufficient amount of dehydration.

  The as-synthesized ZSM-48 product also contains the diquaternary ammonium compound or the respective diquaternary ammonium compound that was used as the directing agent during its synthesis. Thus, prior to use, the product is typically activated by removing organic material, leaving an active catalytic point in the microporous passage of the molecular sieve opening for contact with the feedstock. It is. The activation process is typically accomplished by heating the as-synthesized ZSM-48 product at a temperature of about 200 ° C. to about 800 ° C., typically in the presence of an oxygen-containing gas. .

  If ZSM-48 produced by this method is used as a catalyst, it may be desirable to combine ZSM-48 with other materials that are resistant to the temperatures and other conditions used in organic conversion processes. . These materials include catalytically active and inactive materials, and synthetic or natural zeolites, and inorganic materials such as clays, silica, and / or metal oxides. The latter may be either natural or gelatinous precipitate or gel type (including a mixture of silica and metal oxide). Using a catalytically active material in combination with ZSM-48 produced by the present process can improve the conversion and / or selectivity of the catalyst in certain organic conversion processes. The inert material suitably serves as a diluent to control the amount of conversion in a given process, so that the product is economical without using other means to control the reaction rate. Can be obtained. These materials may be incorporated into natural clays such as bentonite and kaolin to improve the crush strength of the catalyst under commercial operating conditions. These materials (ie clays, oxides, etc.) function as binders for the catalyst. It would be desirable to provide a catalyst that has good crush strength. This is because, in petroleum refineries, catalysts are often subject to harsh handling, tending to break the catalyst into powdered materials, resulting in processing problems. These clay binders are used for the purpose of improving the crushing strength of the catalyst.

  Natural clays that can be complexed with ZSM-48 produced by this method include montmorillonite and kaolin systems. These systems include subbentonite, and kaolin (commonly known as Dixie, McNamee, Georgia, and Florida clay) or others (the main mineral components are halloysite, kaolinite, dickite, nacrite, or anarchite). Site). These clays can be used in the raw state as originally mined or initially subjected to calcination, acid treatment, or chemical modification. Binders useful for complexing with ZSM-48 also include inorganic oxides, particularly alumina.

  In addition to the materials described above, ZSM-48 produced by the present method is a porous matrix material such as silica-alumina, silica-magnesia, silica-zirconia, silica-tria, silica-beryllia, silica-titania, and the like. Can be combined with ternary compositions such as silica-alumina-tria, silica-alumina-zirconia, silica-alumina-magnesia, and silica-magnesia-zirconia. The relative proportions of the finely divided ZSM-48 and the inorganic oxide gel matrix vary widely, with the ZSM-48 content ranging from about 1 to about 90 wt% of the composite, more usually Is in the range of about 2 to about 70 wt%, especially when the composite is prepared in bead form.

  The ZSM-48 produced herein can be used as a sorbent and catalyst in a wide variety of organic conversion processes, but is generally for use as a hydrocarbon dewaxing catalyst. For these applications, it may be desirable to use ZSM-48 in combination with a metal component capable of providing a catalyst having a hydrogenation-dehydrogenation function. Suitable metal components include tungsten, vanadium, molybdenum, rhenium, nickel, cobalt, chromium, manganese, or noble metals (such as platinum or palladium). These components can be exchanged into the composition, impregnated therein, or physically mixed thoroughly therewith. These components can be impregnated therein or on it, for example, in the case of platinum, by treatment with a solution containing platinum metal-containing ions. Accordingly, suitable platinum compounds include various compounds including chloroplatinic acid, platinum chloride, and platinum ammine complexes.

  The catalyst comprising ZSM-48 produced by the present process is particularly useful as a lubricant-based dewaxing catalyst. These feedstocks are wax-containing feedstocks boiling in the lubricating oil range and typically have a 10% distillation point above 650 ° F. (343 ° C.). This is measured by ASTM D86 or ASTM D2887. These raw materials may be derived from a number of materials. Oils derived from solvent refining processes (raffinates, partially solvent dewaxed oils, dewaxed oils, distillate oils, vacuum gas oils, coker gas oils, slack waxes, foots oils, etc.), Fischer-Tropsch waxes and the like. Preferred raw materials are slack wax and Fischer-Tropsch wax. Slack waxes are typically derived from hydrocarbon feedstocks by solvent or propane dewaxing. Slack waxes contain some residual oil and are typically deoiled. Foots oil is derived from deoiled slack wax. Fischer-Tropsch wax is prepared by a Fischer-Tropsch synthesis process.

The dewaxing conditions for these lubricating oil bases typically include a temperature of 426 ° C. or less (such as about 250 ° C. to about 400 ° C., such as about 275 ° C. to about 350 ° C.), a pressure of about 791 to about 20786 kPa ( 100-3000 psig) (such as about 1480 to about 17339 kPa (200-2500 psig)), liquid space velocity of about 0.1 to about 10 hr- ¹ (such as about 0.1 to about 5 hr- ¹ ), and hydroprocessing gas ratio about 45 to about ^{1780m 3 / m 3 (250~10000scf /} B) ( about 89 to about ^{890m 3 / m 3 (500~5000scf /} B) , etc.).

In addition, the catalyst comprising ZSM-48 produced by the present process can also be used for the hydroisomerization of normal paraffins, particularly when provided with a hydrogenation component (eg, platinum). Typically, hydroisomerization is performed at a temperature of about 100 ° C. to about 400 ° C. (about 150 ° C. to about 300 ° C.) using hydrogen with a hydrogen / hydrocarbon molar ratio of about 1: 1 to about 5: 1. Etc.), at a liquid space velocity of about 0.01 to about 2 hr ⁻¹ (such as about 0.25 to about 0.50 hr ⁻¹ ).

  The invention will now be described in more detail with reference to the following non-limiting examples.

Example 1: Preparation mixture of high activity ZSM-48 using a diquaternary -5 and low ^OH -1 / SiO ₂ ratio, the water 1040 g, 2 bromide penta benzalkonium (50% solution) 45 g, Ultra sill [Ultrasil It was prepared from 200 g silica, 11 g sodium aluminate solution (45%), and 36 g 50% sodium hydroxide solution. Then 5 g of ZSM-48 seed crystals were added to the mixture. The mixture had the following molar composition: That is,
SiO ₂ / Al ₂ O ₃ : 102
H ₂ O / SiO ₂ : 20
OH ⁻ / SiO ₂ : 0.17
Na ⁺ / SiO ₂ : 0.17
Diquaternary _-5 / SiO 2: 0.02
It is.

The mixture was reacted in a 2 liter autoclave at 320 ° F. (160 ° C.) with stirring at 350 RPM for 48 hours. The product was filtered, washed with deionized (DI) water and dried at 250 ° F. (120 ° C.). The XRD pattern of the as-synthesized material (see Figure 1-A) showed a typical pure phase for the ZSM-48 topology. SEM of the as-synthesized material (see FIG. 1-B) showed that the material consisted of aggregates of elongated needle crystals. The as-synthesized crystals were converted to the hydrogen form by performing three types of ion exchange with an ammonium nitrate solution at room temperature, followed by drying at 250 ° F. (120 ° C.) and 1000 ° F. (540 ° C.). For 6 hours. The resulting ZSM-48 crystals had a SiO ₂ / Al ₂ O ₃ molar ratio of 90.4, a surface area of 265 m ² / g, and an alpha value of 69.

Example 2 (Comparative Example): diquaternary -5, low ^OH -1 / SiO ₂ ratio, and the high _SiO 2 / _Al 2 _{O 3} prepared mixture of active ZSM-48 in the use of water 1100 g, 2 bromide penta Prepared from 65 g of metonium (50% solution), 228 g of Ultrasil silica, 6 g of sodium aluminate solution (45%), and 45 g of 50% sodium hydroxide solution. The mixture had the following molar composition: That is,
_{SiO 2 / Al 2 O 3:} 195
H ₂ O / SiO ₂ : 19
OH ⁻ / SiO ₂ : 0.17
Na ⁺ / SiO ₂ : 0.17
Diquaternary _-5 / SiO 2: 0.027
It is.

The mixture was reacted in a 2 liter autoclave at 320 ° F. (160 ° C.) with stirring at 350 RPM for 48 hours. The product was filtered, washed with deionized (DI) water and dried at 250 ° F. (120 ° C.). The XRD pattern of the as-synthesized material (see Figure 2-A) showed a typical pure phase for the ZSM-48 topology. An SEM of the as-synthesized material (see FIG. 2-B) showed that the material consisted of aggregates of fibrous crystals. The resulting as-synthesized crystals of ZSM-48 _had a molar ratio of about 170/1 of SiO 2 / _Al 2 _{O 3.}

Example 3 (Comparative Example): Preparation mixture of high activity ZSM-48 using a diquaternary -5 and high ^OH -1 / SiO ₂ ratio, water 360 g, 2 bromide penta benzalkonium (50% solution) 39g, Aerosil Prepared from 35.6 g [Aerosil] 130 silica, 6.9 g Al (NO ₃ ) ₃ xH ₂ O, and 14.4 g 50% sodium hydroxide solution. Then 5 g of ZSM-48 seed crystals were added to the mixture. The mixture had the following molar composition: That is,
SiO ₂ / Al ₂ O ₃ : 60
H ₂ O / SiO ₂ : 40
OH ⁻ / SiO ₂ : 0.33
Na ⁺ / SiO ₂ : 0.33
Diquaternary -5 _/ SiO 2: 0.1
It is.

The mixture was aged at room temperature with stirring at 100 rpm for 24 hours and then reacted at 320 ° F. (160 ° C.) in a 600 ml autoclave for 96 hours with stirring at 100 RPM. The product was filtered, washed with deionized (DI) water and dried at 250 ° F. (120 ° C.). The XRD pattern of the as-synthesized material showed a typical phase for the ZSM-48 topology. SEM of the as-synthesized material indicated that the material consisted of aggregates of fibrous crystals. The resulting as-synthesized ZSM-48 crystals _had a molar ratio to 52/1 of SiO 2 / _Al 2 _{O 3.}

Example 4: Preparation mixture of high activity ZSM-48 using a diquaternary -5 low ^OH -1 / SiO ₂ ratio, water 1195G, 2 bromide penta benzalkonium (50% solution) 69 g, aerosil [Aerosil] Prepared from 228 g of 200 silica, 22.2 g of 45% sodium aluminate, and 41 g of 50% sodium hydroxide solution, and 1.3 g of 47% H ₂ SO ₄ solution. Then 10 g of ZSM-48 seed crystals were added to the mixture. The mixture had the following molar composition: That is,
_{SiO 2 / Al 2 O 3:} 62
H ₂ O / SiO ₂ : 21
OH ⁻ / SiO ₂ : 0.18
Na ⁺ / SiO ₂ : 0.18
Diquaternary _-5 / SiO 2: 0.03
It is.

The mixture was reacted in a 2 liter autoclave at 320 ° F. (160 ° C.) with stirring at 250 RPM for 96 hours. The product was filtered, washed with deionized (DI) water and dried at 250 ° F. (120 ° C.). The XRD pattern of the as-synthesized material (see Figure 3-A) showed a typical phase for the ZSM-48 topology. An SEM of the as-synthesized material (see FIG. 3-B) indicated that the material consisted of elongated needle-like or fibrous crystal aggregates. The as-synthesized crystals were converted to the hydrogen form by performing three types of ion exchange with an ammonium nitrate solution at room temperature, followed by drying at 250 ° F. (120 ° C.) and 1000 ° F. (540 ° C.). For 6 hours. The resulting ZSM-48 crystals had a SiO ₂ / Al ₂ O ₃ molar ratio of about 60, an alpha value of 120, and a surface area of 325 m ² / g, and an n-hexane sorption amount of 42.1 mg / g.

Example 5: Preparation of highly active ZSM-48 using a mixture of diquaternary-5 and diquaternary-6 (diquaternary-5 / diquaternary-6 molar ratio 2.8)
1200 g of water, 17 g of hexamethonium dichloride (56% solution), 60 g of pentamethonium dibromide (50% solution), 228 g of Ultrasil silica, 16 g of sodium aluminate solution (45%), and Prepared from 40 g of 50% sodium hydroxide solution. Then 10 g of ZSM-48 seed crystals were added to the mixture. The mixture had the following molar composition: That is,
_{SiO 2 / Al 2 O 3:} 81
H ₂ O / SiO ₂ : 20
OH ⁻ / SiO ₂ : 0.17
Na ⁺ / SiO ₂ : 0.17
Diquaternary _-5 / SiO 2: 0.025
Diquaternary _-6 / SiO 2: 0.009
It is.

The mixture was reacted in a 2 liter autoclave at 320 ° F. (160 ° C.) with stirring at 350 RPM for 48 hours. The product was filtered, washed with deionized (DI) water and dried at 250 ° F. (120 ° C.). The XRD pattern of the as-synthesized material (FIG. 4-A) showed a product that had a ZSM-48 topology with trace amounts of ZSM-50 impurities. SEM of the as-synthesized material (FIG. 4-B) showed that the material consisted of elongated needle / fibrous crystal aggregates. The as-synthesized crystals were converted to the hydrogen form by performing three types of ion exchange with an ammonium nitrate solution at room temperature, followed by drying at 250 ° F. (120 ° C.) and 1000 ° F. (540 ° C.). For 6 hours. The obtained ZSM-48 crystals have a SiO ₂ / Al ₂ O ₃ molar ratio of 74.2, an alpha value of 57 (Na = 960 ppm), a surface area of 222 m ² / g, and an n-hexane sorption amount of 33.4 mg / g. Had.

Example 6: Preparation of highly active ZSM-48 using a mixture of diquaternary-5 and diquaternary-6 (diquaternary-5 / diquaternary-6 molar ratio is 1)
1200 g of water, 17 g of hexamethonium dichloride (56% solution), 23 g of pentamethonium dibromide (50% solution), 228 g of Ultrasil silica, 16 g of sodium aluminate solution (45%), 98 Prepared from 1.3 g of% H ₂ SO ₄ solution and 40 g of 50% sodium hydroxide solution. Then 10 g of HA-ZSM-48 seed crystals (SiO ₂ / Al ₂ O ₃ = about 70/1) were added to the mixture. The mixture had the following molar composition: That is,
SiO ₂ / Al ₂ O ₃ = 81
H ₂ O / SiO ₂ = 20
OH ⁻ / SiO ₂ = 0.17
Na ⁺ / SiO ₂ = 0.17
Diquaternary-5 / SiO ₂ = 0.01
Diquaternary-6 / SiO ₂ = 0.01
It is.

The mixture was reacted in a 2 liter autoclave at 320 ° F. (160 ° C.) with stirring at 350 RPM for 48 hours. The product was filtered, washed with deionized (DI) water and dried at 250 ° F. (120 ° C.). The XRD pattern of the as-synthesized material (FIG. 5-A) showed a typical pure phase for the ZSM-48 topology. SEM of the as-synthesized material (FIG. 5-B) shows that the material is agglomerated with elongated needles having a lower ratio of L / D (crystal length / diameter) compared to Example 5. It showed that it was made of things. The as-synthesized crystals were converted to the hydrogen form by performing three types of ion exchange with an ammonium nitrate solution at room temperature, followed by drying at 250 ° F. (120 ° C.) and 1000 ° F. (540 ° C.). For 6 hours. The resulting ZSM-48 crystals _had a molar ratio of about 71 of SiO 2 / _Al 2 _{O 3,} alpha value 110, surface area 281m ² / g, and n- hexane sorption amount 42.1 mg / g.

Example 7: Preparation of catalyst for n-decane test A mixture was prepared by combining H-type ZSM-48 crystals from Example 4 with alumina. The powder was mixed together using a mortar and pestle and subsequently pelletized and classified to 14/24 mesh. This material was then dried at 250 ° F. (120 ° C.) and calcined at 1000 ° F. (540 ° C.) in air for 6 hours. The calcined material is then impregnated with platinum by incipient wetness using tetraammineplatinum nitrate, subsequently dried at 250 ° F. (120 ° C.) and calcined in air at 680 ° F. (360 ° C.) for 3 hours. did. Hydrogen chemisorption (platinum dispersion) data for this material showed a dispersion of 83%.

Example 8: n-decane test The catalyst from Example 7 was evaluated in an n-decane isomerization apparatus in the atmosphere. Approximately 1 g of catalyst classified on 14/24 mesh was used for this test. The sample was first heated to 500 ° F. (260 ° C.) under nitrogen and then the flow was switched to hydrogen. After the system was cooled to the first set point 325 ° F. (163 ° C.) and after running hydrogen and n-decane through this reactor at this temperature, an on-line gas chromatograph was The exiting product was analyzed until the next set point temperature was reached. The catalyst was evaluated at a total of nine different temperatures within the range of 325 ° F. (163 ° C.) to 495 ° F. (257 ° C.). Data was collected and analyzed. The results are shown in FIGS. 6-A and 6-B. Thus, at 400 ° F. (204 ° C.), almost 80% of n-decane has been converted (FIG. 6A), and the selectivity to iso-decane is 50-60% (FIG. 6). -B) will be understood.

  Although the present invention has been described and illustrated by reference to specific embodiments, those skilled in the art will recognize that the invention is a reference to variations not necessarily illustrated herein. I will. For this reason, reference will now be made solely to the appended claims for purposes of determining the true scope of the present invention.

Claims (19)

A method of manufacturing ZSM-48, comprising:
(A) The following ingredients:
At least one silica source,
At least one alumina source,
At least one hydroxyl ion source,
The following formula:
(CH ₃ ) ₃ N ⁺ (CH ₂ ) ₅ N ⁺ (CH ₃ ) ₃
Providing an aqueous reaction mixture comprising at least one ion source of ^diquaternary alkylammonium (R ²⁺ ) ions represented by
The reaction mixture has the following molar ratio:
R ^2+: _SiO 2 0.1 than SiO _{2: Al} 2 _O 3 less than 100 OH ^-: step has a composition comprising less than _SiO 2 0.2, and (b) the reaction mixture, to produce the ZSM-48 And a method for producing ZSM-48, comprising a step of crystallizing under conditions effective for the production of ZSM-48. The reaction mixture has the following molar ratio:
R < ₂ ⁺ >: SiO2 0.01-0.05
SiO ₂ : Al ₂ O ₃ 50 to less than 100-100 OH ⁻ : SiO ₂ 0.1 to 0.2
The method of claim 1, comprising a composition comprising: The method of claim 1, wherein the reaction mixture has a H ₂ O: SiO ₂ molar ratio of less than 30. The method of claim 1, wherein the reaction mixture further comprises a sodium cation source and has a Na ⁺ : SiO ₂ molar ratio of less than 0.2. The reaction mixture is represented by the formula (CH ₃ ) ₃ N ⁺ (CH ₂ ) _n N ⁺ (CH ₃ ) ₃ , wherein n is 3, 4, 6, 7, 8, 9 or 10. The method of claim 1 further comprising an ion source of said further diquaternary alkylammonium ions. The reaction mixture also contains claims, characterized in that it further comprises a formula ^{_{(CH 3) 3 N + (}} CH 2) 6 N + (CH 3) ion source further diquaternary alkylammonium ion represented by ₃ Item 6. The method according to Item 5. All diquaternary alkylammonium in the reaction mixture the molar ratio of SiO ₂ The method of claim 6, characterized in that less than 0.1.   The method according to claim 1, wherein the conditions in the step (b) include a temperature of 120 ° C. to 200 ° C. and 12 to 200 hours.   The method of claim 1, wherein the reaction mixture comprises a ZSM-48 seed crystal.   10. The method of claim 9, wherein the ZSM-48 seed is present in an amount from 50 wppm to 50,000 wppm of the reaction mixture. A method of manufacturing ZSM-48, comprising:
At least one silica source,
At least one alumina source,
At least one hydroxyl ion source,
The following formula:
(CH ₃ ) ₃ N ⁺ (CH ₂ ) ₅ N ⁺ (CH ₃ ) ₃
At least one ion source of a first diquaternary alkylammonium ion represented by:
The following formula:
(CH ₃ ) ₃ N ⁺ (CH ₂ ) _n N ⁺ (CH ₃ ) ₃
[Wherein n is 3, 4, 6, 7, 8, 9, or 10]
Crystallizing an aqueous reaction mixture comprising at least one ion source of a second diquaternary alkylammonium ion represented by formula (II) and an optional seed crystal. The method according to claim 10, wherein the second diquaternary alkylammonium ion is (CH ₃ ) ₃ N ⁺ (CH ₂ ) ₆ N ⁺ (CH ₃ ) ₃ . The method of claim 10, wherein the reaction mixture has a SiO ₂ : Al ₂ O ₃ molar ratio of less than 100. The reaction in the mixture, the sum of said first di-quaternary alkyl ammonium ion and the second di-quaternary alkyl ammonium ion molar ratio of SiO ₂ is claim and less than 0.1 10 The method described in 1.   The method of claim 10, wherein the reaction mixture comprises a ZSM-48 seed crystal.   16. The method of claim 15, wherein the ZSM-48 seed is present in an amount from 50 wppm to 50,000 wppm of the reaction mixture.   The method according to claim 10, wherein the crystallization conditions include a temperature of 120 ° C. to 200 ° C. and 12 to 200 hours.   A hydrocarbon raw material dewaxing method comprising the step of bringing a hydrocarbon raw material into contact with ZSM-48 prepared by the method according to claim 1 under dewaxing conditions.   A hydrocarbon raw material dewaxing method comprising the step of bringing a hydrocarbon raw material into contact with ZSM-48 prepared by the method according to claim 10 under dewaxing conditions.

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